Hacking apparatus and method



April 26, 1960 A. B. SEGUR 2,934,222

HACKING APPARATUS AND METHOD Filed 001:. 11, 1956 2 Sheets-Sheet 1 mm'lm WWW-H."

INVENTOR: I I9 @afidW i B) r- ATTORNEY? April 26, 1960 l A. B. SEGUR INVE/V TOR A TTORN BVM HACKING APPARATUS AND METHOD Asa B. Segur, Oak Park, Ill.

Application October 11, 1956, Serial No. 615,268

8 Claims. (Cl. 214-8) This invention relates to a hacking apparatus and method and, more specifically, to a method and apparatus for quickly and erficiently stacking ceramic articles such as unfired brick and tile.

In the manufacture of ceramic articles, extruded ribbons of clay are segmentally cut into blanks and these blanks are then stacked to form a hack-that is, an arrangement suitable for drying and for further processing of the blanks in a tunnel or periodic kiln. Usually the brick or tile blanks are manually stacked by individually placing each of the articles upon a rail car or other vehicle for drying, and, in the case of periodic kiln operation, the blanks are again stacked on a bench for firing after they have been dried.

In manual hacking as it is commonly performed, Workers are required to stoop down in order to lay the lower courses or layers and must reach upwardly to arrange the top courses of the hack. In addition, the workers must often turn 90 or even 180 between the pickup and the disposal of the brick blanks. It is apparent that such stooping and turning action is excessively fatiguing and that inefficiency and relatively low productivity result.

While semi-automatic methods for guiding the hacking of ceramic blanks are now in use (such as the system disclosed in my Patent 2,748,957, issued June 5, 1956), such methods are usually limited to the backing of brick directly upon tunnel kiln cars or upon dryer cars and are therefore unsuitable for general use in conjunction with periodic kilns. Furthermore, such systems are not satisfactory where different types and sizes of ceramic products are to be loaded upon each of the cars or where the cars themselves are too wide to permit the proper placement of the blanks by workers positioned adjacent thereto. In addition, the guide means generally fail to permit the numerous variations in brick or tile arrangement necessary to achieve proper drying or firing .of ceramic articles having different compositions and shapes.

Therefore, it is one of the main objects of the present invention to provide an improved method and apparatus for the hacking of ceramic products which overcomes the aforementioned defects and disadvantages. Another object is to provide an etlicient method and apparatus for handling brick and similar material which substantially eliminates waste motion and greatly reduces the fatiguing manual operations involved in the hacking procedure. In this connection it is a specific object to provide a hacking apparatus wherein workers remain in substantially the same position throughout the hacking operation and are able to stack the brick blanks of each layer without bending, stooping or turning. A further object is to provide means for easily and accurately guiding the unfired bricks as they are being stacked, the means being interchangeable for positioning the bricks in any selected arrangement. A still further object is to provide a method and apparatus for hacking ceramic products which is suitable for use in connection with either tunnel or periodic kilns.

Other objects will appear from the specification and drawings in which:

Figure 1 is a broken top plan view of a brick hacking station; Fig. 2 is a vertical cross sectional view taken along line 2-2 of Fig. 1 and showing the movable carrier in front elevation; Fig. 3 is a vertical section taken along line 3-3 of Fig. 1; Fig. 4 is a vertical section similar to Figs. 2 and 3 and taken along line 44 of Fig. 1; Fig. 5 is a broken side elevation of the carrier shown in Fig. 2; Fig. 6 is a side elevation of the carrier similar to Fig. 5 but showing the carrier in a partially loaded condition corresponding with Fig. 3; Fig. 7 is a side elevation of a fully loaded carrier corresponding with Fig. 4 of the drawings; Fig. 8 is a perspective view of the hack supported by the carrier in fully loaded condition; Fig. 9 is a perspective view of the grid structure used as a guiding means for hacking the lower courses of brick; Fig. 10 is a perspective view of another grid guide for hacking the intermediate layers or courses of brick (Figs. 3 and 6); and Fig. 11 shows a third grid in perspective for arranging the upper layers of brick upon the carrier (Figs. 4 and 7).

Referring to the drawings, Figure 1 shows a backing apparatus generally designated by the numeral 10 and essentially comprising a frame 11, conveyors 12 and 13, and a carrier 14. In the illustration given, the frame consists of a pair of horizontal and parallel guide members or beams 15 and 16 respectively. These beams are spaced from each other and are supported at uniform distances above a floor or platform surface by any suitable supporting means, such as standards 17.

In the manufacture of brick or tile, a ribbon of clay is extruded from a suitable brick making machine and is cut into segments of uniform length. The stream of blanks is then divided and the ceramic units are carried towards the hacking apparatus on conveyors 12 and 13. It is to be understood that the number of bricks carried by each of the conveyor belts may be the same or may be different, depending upon the number and position of workers hacking the bricks upon carriers 14.

Conveyor belts 12 and 13 are entrained about drive pulleys 18 and travel forwardly alongside the parallel guide members of the frame. If desired, idler pulleys (not shown) may be mounted along frame members 15- and 16 to maintain the horizontal belts at uniform distances above the floor surface. Preferably, the conveyors are disposed at an elevation ranging between 28 and 31 inches above the fioor surface for reasons which will appear shortly. It is to be noted that the conveyors and theframe members 15 and 16 are supported atsubstantially the same elevation (Figs. 2-4).

As shown most clearly in Figures 57, 'the'carrier structure 14 is movably suspended from a monorail 1-9 which extends longitudinally above the remainder of the hacking apparatus and which is equidistant from the parallel frame members 15 and 16. to a discharge station where all of the bricks or tiles carried by each carrier are simultaneously placed upon a suitable vehicle, such as a tunnel kiln car, or upon a platform from which the stack may be transferred to a periodic kiln by suitable transfer means, such as a fork lift.

In the illustration given, carrier 14 has a bottom wall 20 equipped 'with a plurality of upstanding and uniformly spaced parallel ribs 21. The ribs may be formed in: tegrally with the bottom wall and not only reinforce and; greatly strengthen the carrier structure, but also serve to guide the placement of bricks or other ceramic units in the lower courses and provide a mounting for rollers-22.; As illustrated most clearly in Figs. 2-4, the walls of .each rib are spaced apart along-the. lower portions thereof to accommodate the rollers 22. The rollers may be 1'9- Patenteel Apr. 26, 1960' The monorail leads tatably secured within the recessed ribs by shafts 23 and project downwardly below the bottom of the carrier for movably supporting that carrier during a brick unloading operation. Preferably, each of the elongated ribs is provided with two or more rollers so that the weight of the carrier and its load is uniformly distributed upon the'base or bottom wall 20 when the rollers engage a support surface.

Ribs 21 extend the entire length of base 20 and are provided with corresponding flat vertical surfaces 24 for guiding and supporting ceramic units of the foundation layers during a hacking operation. Sides 25 project upwardly from opposite sides of the base or bottom wall and have their upper portions turned inwardly and downwardly to provide smooth upper surfaces 26 for slidably engaging the lower surfaces of the parallel frame members 15 and 16. The upstanding side flanges 25 also serve to prevent lateral swinging movement of the carrier as the foundation course or layer is set in place.

In Figs. 1, 2 and 6, it will be seen that the carrier is provided with a back wall 27 having an upper portion slightly narrower than the distance between the parallel guide members 15 and 16 of the frame. Hence the edges of this upper portion are engageable with the frame members when the carrier is in the position illustrated in Figs. 1, 2 and to limit lateral movement of the carrier. Rear wall 27 is welded or otherwise secured to the lower end portion of a cantilever support member 28 having a vertical portion 29 and a horizontal portion 30. The horizontal portion extends forwardly above the base or bottom wall 20 of the carrier and is equipped with a hanger 31 which receives the hook 32 of hoist 33. Counterbalancing weights 34 are mounted adjacent the front end of the horizontal portion to offset the weight of the cantilever arm or member behind the point of suspension and a reinforcing rib 35 extends along the support arm to' increase the structural rigidity of that member.

Preferably, the hoist is provided with an electric motor 36 for driving the wheels 37 which ride along monorail 19 and for retracting or extending the cables 38 which support the hook 32. Therefore the motor not only drives the carrier along the track or rail 19 but also elevates or lowers the carrier with reference to that rail. Since the hoist structure is entirely conventional, a more detailed description of that structure is believed unnecessary herein. It is to be noted, however, that other power means for operating the hoist may be employed and that, if desired, the hoist may be adapted for manual operation.

Figures 9, and 11 illustrate three grids designated respectively by the numerals 40, 41 and 42 for directing the placement of ceramic units as they are being hacked. All of the grids are wider than the distance between the parallel frame members and 16 and are provided with members extending longitudinally of the frame and transverse members having raised outer or lateral portions adapted to rest upon the frame members. Similarly, all of the transverse members of the grids are equipped with intermediate portions below the end portions and slightly narrower or shorter than the distance between the frame members. Hence, the lateral end portions support the grids upon the frame members while the transverse intermediate portions engage the inner opposing surfaces of frame members and prevent lateral movement of the grids with reference thereto. The grids may be formed of aluminum or any other sturdy and relatively light material.

In Figures 9 through 11, it will be seen that the grids are each composed of interconnected longitudinal and transverse members. The transverse bars or members 43 and 44 of grids 40 and 42 have lower intermediate portions 45 and 46 and elevated end portions 47 and 48, respectively. Grid 40 has the general configuration of the letter U and is provided with a pair of parallel and longitudinal side bars 49 and 49a extending rearwardly like the grids previously described is equipped with a plurality of transverse bars or members 56, 57, 58 and 59.

However, all of the grids perform the same basic function of guiding the placement of bricks upon carrier 14, the relationship of the interconnected members of each grid being responsible, at least in part, for the characteristic arrangement or pattern of ceramic units for the respective layers or courses of units in each hack. It is to be understood, of course, that grids having different bar arrangements may be employed, depending upon the brick pattern desired and the size and composition of the bricks or other ceramic units, and that a greater (or smaller) number of different grids may be employed to obtain any desired brick arrangement.

To insure proper positioning of the ceramic units upon the carrier, frame members 15 and 16 may be provided with stops 60. These stops engage the front edges of the grids and prevent forward displacement of the same upon the frame during a hacking operation. Hence the guide members of the grids and the members provided by the stationary frame cooperate to direct the placement of discrete ceramic units upon the carrier.

In the operation of the apparatus the suspended carrier 14 is first positioned as shown in Figs. 2 and 5 (and the upper portion of Fig. l) with the side flanges and the base or bottom wall of the carrier disposed below the frame members. Grid (Fig. 9) is then placed upon the frame so that the intermediate portion of the transverse bar is seated between the frame members with the forward surface of that bar abutting stops 60. Green bricks or other unfired ceramic units, designated by the letter X in the drawings, are delivered to the hacking station by conveyors 12 and 13 and are placed upon the carrier by workers standing adjacent opposite sides of the frame. Preferably, the bricks of the lower two layers of the first course are hacked while the carrier is in the position shown, the bricks extending longitudinally of the carrier and frame and being seated against the flat surfaces 24 of the carrier ribs 21. Hence the ribs of the carrier and the parallel members of the frame control the lateral disposition of the bricks while the transverse bar of the grid orients the bricks lengthwise. It is to be noted that the distance between the adjacent ribs of the carrier is substantially greater than the thickness of the bricks placed therebetween. This difference not only allows the carrier to accommodate bricks or tile of different size but also spaces the longitudinal rows of bricks to increase the circulation of air therebetween and to speed the subsequent drying or firing operation.

While bricks X or the first two courses are shown longitudinally disposed between the ribs of the carrier, it will be understood that the bricks of the foundation layers or half-courses may be transversely positioned and that such an arrangement is within the scope of this invention. Furthermore, while conventional bricks are illustrated, other discrete ceramic units such as tiles may be hacked upon the carrier.

After the foundation course is laid, the carrier is lowered by hoist 33 into the position shown in Figs. 3, 6 and the intermediate portion of Fig. 1, As the carrier moves downwardly, grid 40 is removed and grid 41 is then placed upon the frame with the front surface of its foremost transverse bar against stops 60. The next two layers of brick are then stacked upon the carrier, the bricks extending transversely and being arranged in spaced rows by transverse guide members 56, 57, 58 and 59. It will be noted that the edges of each of the flat transverse bars has 56, '57 and 58 engage the opposing sides. of twoadjacent rows of bricks in each layer, while the foreward bar 59 directs the placement of only one transverse row of bricks. In addition, the fiat bars are spaced farther from each other than the thickness of the bricks of the two rows disposed therebetween. Hence, spaces for the circulation of air are provided between all of the parallel rows of each brick layer.

Finally, after the bricks of the intermediate layers have been arranged in the preselected pattern defined by the configuration of grid 41, the carrier is lowered into the position illustrated in Figs. 4, 7 and the lower part of Fig. l, and grid 41 is replaced by grid 42 (Fig. ll). Grid 42 is set in place in the manner already described and the upper courses of brick are laid in spaced longitudinal rows. Like the fiat bars 56-58 of grid 41, bars 50, 51, 53 and 54 of grid 42 each serve to guide the placement of two spaced rows of brick in each layer. The central bar 52, however, engages only a single row because of the uneven number of rows in each layer of a conventional hack. After the stack is completed, grid 42 is removed and the hack is conveyed by carrier 14 along monorail 19 to a suitable discharge station. The complete hack is illustrated in Fig. 8 and is designated generally by the numeral 61.

From the foregoing it is believed evident that the grids 40, 41, and 42 serve as removable guide structures and cooperate with the parallel members of the frame 11 to define a border for directing the placement of bricks. While only three grids are shown in the drawings, it will be understood that other grids having different arrangements of longitudinal and transverse bars may be used to produce the most suitable pattern for any particular type of ceramic material. In addition, the use of each grid is not limited to the laying courses comprising only two layers of brick since a greater or smaller number of layers may be guided with each of the grids, depending upon the particular arrangement of brick desired.

Fig. 1 shows an arrangement wherein each carrier advances forwardly as the vertical distance between the frame members and the carrier is increased. Such relocation is desirable where two or more carriers are simultaneously loaded and where several men are employed for hacking the brick at each carrier location. However, where the brick is to be hacked upon one carrier at a time, the carrier is preferably maintained at the same horizontal position with reference to the frame as the carrier is lowered beneath the frame to receive additional courses of brick.

Since the horizontal frame members and the conveyors 12 and 13 are adjacent each other and are approximately waist high, workers standing on opposite sides of the frame may easily and quickly transfer the ceramic articles from the conveyor belts to the carrier or carriers without stooping, bending or turning. The plane of application, that is, the elevation of the surface upon which the bricks are placed, remains substantially the same throughout the hacking operation, thereby eliminating the stooping or reaching commonly involved in present hacking procedures. Consequently the structure of the present invention eliminates many of the motions required in conventional hacking, thereby increasing the speed and reducing the cost of brick hacking operations.

In the embodiment of my invention shown in the drawings, the carrier means for supporting the bricks at different successive elevations as the hack is formed has been illustrated as a platform carrier suspended from a monorail. It is apparent, however, that other carrier structures might be provided for receiving the stacked brick, such as a rail car or other vehicle, and that the means for increasing the vertical distance between the carrier and the frame upon which the grids are removably mounted might be disposed below the carrier instead of above the same.

While in the foregoing I have set forth my invention in considerable detail for purposes of illustration, it will be understood by those skilled in the an that many of these details may be varied considerably without (18? parting from the spirit and scope of the invention.

I claim:

1. 'In an apparatus for stacking discrete units in :successive layers, a frame, a carrier adapted to be positioned adjacent said frame for receiving said units thereon, a removable grid supported by said frame above said carrier for directing said units into a guided :pattern as they are manually lowered into preselected positions'.directly upon a course of units supported by. said carrier, said grid having spaced interconnected members defining pockets open at both their upper and lower ends for guiding the manual placement of said units, and means for increasing the vertical distance between said carrier and said frame as successive layers of said units are stacked upon the carrier, said frame cooperating with said guide means to restrain downward movement of the guide means with reference to said frame as the vertical distance between the frame and carrier is increased.

2. The structure of claim 1 in which conveyor means are provided at substantially the same elevation as said guide means to deliver a continuous single-file series of said units towards said frame for stacking of the same upon said carrier.

3. In an apparatus for stacking ceramic units, a frame, a carrier adapted to be positioned adjacent said frame for receiving ceramic units thereon, a plurality of grids each adapted to be individually and removably mounted upon said frame above said carrier for guiding said ceramic units into a preselected pattern of spaced rows as they are manually lowered into preselected positions onto the carrier or a load of units carried thereby, said grid having spaced interconnected members defining pockets open at both their upper and lower ends for guiding the manual placement of said units, and means for increasing the vertical distance between said carrier and said frame as successive layers of ceramic units are stacked upon the carrier, said frame restraining downward movement of the guide structure supported thereby as the vertical distance between said carrier and said frame is increased.

4. The structure of claim 3 in which conveyor means are provided at substantially the same elevation as said frame for delivering a single-file series ceramic units thereto.

5. An apparatus for the manual stacking discrete ceramic units in successive layers comprising a frame having horizontal frame members defining a space therebetween, a carrier adapted to be positioned between the members of said frame for receiving ceramic units thereon, a guide structure removably supported upon said frame above said carrier and having transverse guide members extending between the horizontal members of said frame and defining pockets being open at the upper and lower ends thereof, said guide members cooperating with said frame members to define a predetermined limiting border for directing the manual placement of ceramic articles directly upon said carrier or upon a load carrier thereby, and means for increasing the vertical distance between said carrier and said horizontal frame members as successive layers of said ceramic units are stacked upon the carrier, said frame restraining downward movement of said guide structure with reference thereto as the vertical distance between said frame and said carrier is increased.

6. The structure of claim 5 in which said guide structure is also provided with longitudinally extending guide members for directing said units into spaced rows as they are placed upon said carrier.

7. The structure of claim 5 in which conveyor means are provided at substantially the same elevation and adjacent said frame members for conveying a continuous single-file series of ceramic units thereto.

placement of said units directly upon said carrier and upon a load carried thereby, said grid having interconnected members defining spaces open at both their upper and lower ends for guiding the manual placement of said ceramic units, and means for successively lowering said carrier below said frame members as layers of ceramic units are stacked upon the carrier, said frame cooperatingwith said guide means for restraining downward movement of the same when said carrier is lowered.

References Cited in the file of this patent UNITED STATES PATENTS Myers Jan. 11, 1921 Hoiles Get. 11, 1955 Segur June 5, 1956 Johnson Oct. 9, 1956 Ehlers Nov. 6, 1956 

